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Fuel Tank: Installation

WARNING: This page is about a different car, the 2007 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL FUEL TANK ASSEMBLY 
    1. Set the fuel tank on a mission jack.
    2. Lift up the mission jack.
    3. Fold back the 2 cushion rubbers.
    4. Connect the fuel pump connector and sender gauge connector to the fuel tank.
      NOTE: Be careful not to cut the wirings.
    5. Attach the wire harness to the 4 clamps.
      Fig 1: Attaching Wire Harness To Clamps
      G04485509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 3 fuel tank bands with the 6 bolts.

      Torque: 40 N.m (408 kgf.cm, 30 ft.lbf) 

  2. INSTALL FUEL TANK FILLER PIPE 
    1. Install the filler pipe with the 2 bolts.

      Torque: 23.5 N.m (240 kgf.cm, 17 ft.lbf) 

    2. Install the filler pipe protector with the 3 bolts.
      Fig 2: Installing Filler Pipe Protector With Bolts
      G04485510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Connect the filler pipe hose to the fuel tank.
      Fig 3: Connecting Filler Pipe Hose To Fuel Tank
      G04485511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CONNECT FUEL TANK BREATHER HOSE 
    1. Connect the fuel tank breather hose to the fuel tank.
      NOTE:
      • Before installing the tube connector to the pipe, check the connector for damage and foreign matter.
      • Check that the connector and pipe is securely connected by trying to pull them apart.
  5. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    NOTE: Before installing the tube connector to the pipe, check the connector for damage and foreign matter.
    Fig 4: Connecting Fuel Tank Breather Hose To Fuel Tank
    G04485512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the main tube connector to the pipe. Push the 2 parts together firmly until a "click" sound is heard.
      NOTE: Check that the connector and pipe are securely connected by trying to pull them apart.
    2. Connect the EVAP hose to the fuel tank.
      Fig 5: Connecting EVAP Hose To Fuel Tank
      G04485513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 FLOOR UNDER COVER 
    1. Install the floor cover with the clip and 2 nuts.
  7. INSTALL FRONT FLOOR COVER 
    1. Install the floor under cover with the 3 clips, bolt and nut.
      Fig 6: Installing Floor Under Cover With Clips, Bolt And Nut
      G04485514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY 
    1. Install the parking brake cable with the 2 bolts.
      Fig 7: Installing Parking Brake Cable With Bolts
      G04485515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FUEL TANK CAP 
  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  11. INSPECT FOR FUEL LEAKS (See  CHECK FOR FUEL LEAKAGE  ). 
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